Tool installed connector and process for its installation



May 2 1944 J. RoGoFF Toor.. INSTALLED CONNECTOR AND PRoGEss Foa ITS INS'TALLATION Filed March 19, 1941 2 Sheets-Sheet 1 J. ROGOFF May 2, 1944.

TOOL INSTALLED CONNECTOR AND IROCESS FOR ITS INSTALLATION Filed March I9, 1941 2 Sheets-Sheet 2 n IOR' ATTORNEY www Patented May 2, 1944y ufr-UNITED STATES nPliraN'l, OFFICE TOOL INSTALLED CONNECTOR. AND PROC- ESS FOR ITS INSTALLATION Julian Rogoi, New York, N. Y., assignor to Burndy Engineering Company, Inc., a corporation of New York lApplication March 19, 1941, Serial No. 384,079

2 Claims.

` invntion relates to low cost wire terminals and similar connectors, suitable for installation by meansof a properly designed tool.

Amain object of my invention is to provide a 'very inexpensive wire terminal which is comparable in cost witha solder terminal but which can hey installed without the use of solder.

Another object of my invention is to make it possible to manufacture my connector from sheet metal on high speed,4 automatic machinery.

Still anotherv yobject is toprovide a connector Athat can be installed bylxneans of a simple hand- ;operated tool.-

. Another object of my invention is to provide a connector which will accommodate any one of a `range of wire sizes, withoutchange of any of the parts Vandfwhich can be assembled to any one of y the wires by means of the same tool. z -Another object of my invention is to provide a connector whichV has excellent electrical conductivity and a good mechanical grip.

. I accomplishthese and other objects and obtain new results as will be apparent from the devices described'in the .following description, particularly pointed out in the attached claims, and illustrated in the accompanying ,drawings in which,

Fig. 14 shows a perspective view of a terminal according to my invention in the original condition, l. e., before appliance of the tool shown in Fig. 20.

Fig. 2 shows a longitudinal sectional View of the embodiment shown in Fig. 1, in final condition,

' together'with the end of a cable gripped by the connector, said section taken along the line 2-2 in Fig. 3.

Fig. 3 shows a cross-section taken along the line 3-3 in Fig. 2. y y

Fig. 4 shows a perspective view of another embodiment of my connector, in original condition.

Fig. 5 shows a sectional view of the embodiment 'shown in Fig. 4 in nal condition taken along the line 5-5 in Fig. 6.

Fig. 6 shows a cross-section taken along the line (--Ii` in Fig. 5. K

Fig. 'I shows a perspective view of another embodiment of my connector in original condition.

Fig. 8 shows a sectionalview of the embodiment shown in Fig. 'l in final condition and taken along the line 8---84 in Fig. 9.

Fig. 9 shows a cross-section taken` along the line 9-9 in Fig. 8.

Fig. 10 shows a perspective view of another emf bodiment of my connector in original condition.

Fig. 11` shows a sectionaI view of the embodiment shown in Fig. 10 in iinal condition and taken along the line Ii--II in Fig. 12.

Fig. l2 shows a cross-section taken along the line I2--I2 in Fig. 11.

Fig. 13 shows a perspective view of still another embodiment of my connector in original condition. Fig. 14 shows a sectional view of the embodiment shown in Fig. 13 in nal condition and taken along the line l4-I4 in Fig. 15.

Fig. l5 shows a cross-section taken along the line I5-I5 in Fig. 14.

Fig. 16 shows still another embodiment of my connector seen from above.

Figs. 1'7, 18 and l9-show three subsequent steps of the indenting operation used in bringing my connector into nal shape.

Fig. 20 shows the working head of a tool used in said operation.

Referring particularly to the embodiment of my invention shown in Figs. 1, 2 and 3, numeral I0 indicates the connector with a lug body Il ending in the terminal plate I2 and connected to a U-shaped body section I3. In the final condition, the ends I3a and 13b of the U are bent about the conductor I4, forming a socket. The wall of said socket is impressed by application of a pressing tool whereby the socket is indented into the conductor I4. An upper impression I5a interlocks the overlapping ends I3a and 13b of the U. Said impression runs in longitudinal direction, that is to say, its main dimension is parallel to the central axis of the conductor I4. This impression does not, however, extend as far as the front and back ends of the U, leaving unimpressed margins Ita and IBb at both sides. Thereby the side openings of the socket are not distorted and provide for a gradual compression of the conductor Il, eliminating any tendency to shear strands of the conductor. The lower portion of the socket is, preferably, similarly impressed by a longitudinal impression I5b to insure maximum mechanical grip and electric contact. This impression is located diametrically opposite to said iirst impression.

Referring particularly to the modiiication 3. The lug body 2| has bent portions 29a and 23h whereby a channel running in a direction cross- .y ing the longitudinal direction is formed. This channel shape of the lug body increases the strength of the body at that portion where it is most needed, that is Where the conductor is crimped. In addition, this shape helps to guide the conductor into the proper position in the clamping element, and the bend 29h adjacent the terminal tongue 22 raises the conductor contacting section of the body so that there is suiiicient clearance between the projecting end of the cable |4 and the terminal plate 22.

Referring particularly to the embodiment shown in Figs. '1, 8 and 9, the connector 30 is a body comprising the lug section 3| ending in the terminal plate 32, the U-shaped section 33 with legs 33a and 33h, and the slotted section 31 with two longitudinal slots 38. A section 31a connecting sections 33 and 31 is provided with a hole.31b for the passage of the conductor 34. In the iinal condition, section 31a is bent upward and section 31 bent to the right side into horizontal position. Then the U-legs 33a and 33h pass through the slots 28 forming a socket similarly as the corresponding parts in Figs. 5 and 6. Indenting impressions 35a and 35h are provided as in the precedent modiiications.

Referring particularly to the modification shown in Figs. 10, 11 and l2, the connector 48 comprises a U-shaped section 43, an intermediate section 41a, a slotted section 41 `and a terminal plate 42. In the nal condition the section 41a is bent upward so that the hole 41b provided in this section serves as a passage for the insertion of the cable 44. The U-shaped section 43 is bent to the right side so that the legs 43a and 43h pass through the slots 48 provided in the section 41. Indenting impressions 45a and 45h are provided as in the precedent modii'lcations.

The modification 50 shown in Figs. 13, 14 and l5 is similar to that shown in Figs. 4 to 6, but differs in that the lug body 5I has'the longitudinal slots 58 and the upper body 53 is U-shaped. In the final condition the ends 53a and 53h of the U passing through the slots 58 are bent below the slots. Here the channel-shape formed by bends 59a and 59h, in addition to the advantages previously mentioned, provides a recess for the bent ends 53a and 53b and thereby a fiat position of the connector and the terminal plate' 52.

The modification shown in Fig. 16 is similar to that shown in Figs. 13 to 15, but diners in that the lug body 6I has an additional section 61 extending to the side opposite to the terminal plate 62 in longitudinal direction. Body section 61 has two lateral wings, the original position of which is illustrated by dotted lines as at 61a. In the final condition the wings are clamped about the conductor 64 as at 61 whereby section 51 provides for additional grip and support of the conductor.

All these modifications show longitudinal impressions inthe socket wall indenting into the conductor and leaving unindented margins at the front and at the back side of the socket. In addition to or instead of these impressions and indentations, there may be one or more similar impressions indenting into the conductor at any other portion of the socket wall. In addition to the indent-ations, the inner surface of the socket contacting the conductor may be serrated for better grip. The lug body may be made from sheet metal, preferably of uniform thickness.

The inner distance of the longitudinal slots is approximately equal to the diameter of the largest conductor which the clamping element shall accommodate. The U-legs are of such dimensions and so spaced that they fit into the slots. 'I'he ends of the U-legs may be slightly staked after insertion into the slots to prevent them from dropping out in handling ory transportation. Such staking, however, is done "in a manner that does not interfere with the free sliding of the legs in the slots.

The clamping element is preferably installed inthe following way: First the conductor is inserted between the U-legs. Then the clamping elementis crimped around the conductor whereby a closed tubular socket is formed. Then the wall of the socket is` impressed for indentation into the conductor. In the case of the slotted embodiment, the ends of the U-legs passing beyond the slots may be finally interlocked by applying a flattening pressure to them in the direction toward the slotted body.

My clamping element is adapted forr quick,

easy and inexpensive installation. According to my further invention, such installation may be achieved by using a single tool completing all necessary steps in immediate sequence by one operation of the tool.

An embodiment of an installation tool suitable for this purpose is Ashown in Fig.`20. lThe tool 10 may be pliers-like or of similar character and may have a pair of jaws 1| and 12 shaped according to the special modication of the clamping element to be installed. In the shown example, one jaw,1| of the tool 1|)` ismadewith a longitudinal punch lawith a slight taper 13 along its width. This taper is so designed that, upon closing of the tool, the -jaw 1| will spread the ends of the U-legs, thereby binding the U- shaped body to the slotted body. The other jaw l 12 of the tool 10shas a longitudinalgroove 12a with a round wallto accommodate the head bend of the U. v v v Fig. 17 s hows the connector 84 contacting parts of the jaws 1| and 12 at a larger scale together with a slotted embodiment of the clamping element in cross-section. 'Ihe jaw 1| has a1- ready begun to spread the ends of the U-legs while the jaw 12 has already begun to impress and to indent the head bend of the U.

Upon further closing of the tool, the punch 1|a presses into the wall of the socket and indents said wall into the conductor. At the same time, the grooved portion of the jaw12 presses the U-head and indents it deeper into the conductor. Fig. 18 shows the details of Fig. 17 during this further step of. the operation. Here the ends of the U-legs are more bent to the side.

Further closing of the tool causes still deeper indentations and pressing of the ends of the U- legs against'the slotted bodyl section. vIn the final condition shown. in Fig. 19, these ends are depressed by the jaw` 1| from the shape shown by dotted lines 14 to 'a somewhat flattened shape whereby the said ends are interlocked and a tight permanent assembly is formed.

Both the round groove 12a and the punch 1|a are made slightly less long than the width of the U in direction of the conductorV in order to avoid distortion of the opening edges of the socket 53a and 53D.

My` clamping element can be used for a range of conductor sizes because the socket is formed according to the actual size of the conductor.

For example, in the slotted embodiments the U- legs will slide through the slots until the U-head contacts the conductor. As the U-legs slide through the slots, they are gradually spread by the taper 13 of the punch 1l.

I desire it understood that my invention is not confined to the particular forms or uses shown and described, the samebeing merely illustrative, and that the invention may be carried out in other ways without departing from the spirit of my invention and, therefore, I claim broadly the right to use all equivalent instrumentallties and processes coming within the scope of the appended claims. andI by means of which, objects of my invention are attained and new results accomplished, as Vit is obvious that the particular embodiments herein shown and described are only some of the many that can be employed to attain these objects and to accomplish these results.

I claim: c

1. A sheet metal connector attached to a metal cable, having a U-shaped body section formed into a cable receiving socket and made of malleable metal adapted to be cold worked under pressure; a metal plate made of malleable metal having two parallel slots therein through which the legs of the U-shaped body section extend; said legs bent over to lock the cable receiving socket and the plate in contact with the metal'cable; the metal cable and connector locked to each other by an indentation by which the metal of the connector is cold worked into the metal of the cable.

2. A connector according to claim 1, characterized by having the U-shaped body section and metal plate formed out oi a single sheet of metal, having an aperture between the plate and section to permit the entrance of the cable.

JULIAN ROGOFF. 

